Safety Warning
DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.
Diagnostic Test
On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety procedures. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down. Failure to follow these instructions may result in possible serious or fatal injury.
Read the HIGH-VOLTAGE SAFETY PROCEDURES. Refer to HIGH VOLTAGE SAFETY PROCEDURES .
When the HIGH-VOLTAGE POWER-DOWN PROCEDURE is necessary. Refer to VEHICLE HIGH VOLTAGE POWER DOWN .
Repair any Low or High Voltage DTCs in BPCM, IDCM, MCPA(B) or EVCU before proceeding and recheck operation. Refer to DIAGNOSTIC CODE INDEX .
- Isolate the Digital Crash Output Control circuit between the Occupant Restraint Controller (ORC) and the Battery Pack low voltage connector. Inspect the connectors for damaged or pushed out terminals.
- If the connector(s) or terminals are damaged, repair any problems found in accordance with the Service Information.
- If no problems are found, continue to step 2.
- Measure the resistance of the Digital Crash Output Control circuit between the ORC and the BPCM low voltage harness connectors. Typically should be less than 3.0 ohms.
- If there is excessive resistance in the harness, repair the harness in accordance with the Service Information.
- If no problems are found, continue to step 3.
- Measure the resistance of the Digital Crash Output Control circuit between the ORC and ground. Typically should be less than 3.0 ohms.
- If there is continuity to ground in the harness, repair the harness in accordance with the Service Information.
- If no problems are found, replace the ORC in accordance with the Service Information. Refer to CONTROLLER, OCCUPANT RESTRAINT (ORC), REMOVAL AND INSTALLATION .
- continue to step 4.
- If the DTC returned, replace the High Voltage Battery in accordance with the Service Information. Refer to HIGH VOLTAGE BATTERY, REMOVAL AND INSTALLATION .
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When to See a Mechanic
Stop DIY work and contact a certified mechanic immediately if any of the following apply:
- • You smell fuel, burning insulation, or see smoke.
- • Brakes feel soft, pull hard to one side, or make grinding noises.
- • The engine overheats, stalls repeatedly, or misfires under load.
- • You are missing required tools, torque specs, or safe lifting equipment.
- • You are not confident in the next step or safety outcome.